PORTABLE GENERATOR Starting Watts / 5000 Running Watts Electric Start OWNER S MANUAL & OPERATING INSTRUCTIONS MODEL NUMBER

Transcription

1 OWNER S MANUAL & OPERATING INSTRUCTIONS 6000 Starting Watts / 5000 Running Watts Electric Start PORTABLE GENERATOR MODEL NUMBER SAVE THESE INSTRUCTIONS Important Safety Instructions are included in this manual. MADE IN CHINA REV Santa Fe Springs Road Santa Fe Springs CA USA /

2 AN IMPORTANT MESSAGE ABOUT TEMPERATURE: Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40 C (104 F). When your product is needed your product may be operated at temperatures ranging from -15 C (5 F) to 50 C (122 F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and other vents. Have questions or need assistance? Do not return this product to the store! WE ARE HERE TO HELP! Visit our website: for more info: Product Info & Updates Frequently Asked Questions or Tech Bulletins Product Registration Call our Customer Care Team Toll-Free at: : The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. *We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.

3 Starting Watts / 5000 Running Watts Electric Start PORTABLE GENERATOR Table of Contents Introduction... 1 Introduction... 1 Portable Power Generator... 1 Accessories... 1 This Booklet... 1 Manual Conventions... 2 Safety Rules... 3 Controls and Features... 5 Generator... 5 Power Panel... 6 Parts Included... 7 Wheel Kit... 7 Other... 7 Assembly... 8 Remove the Generator from the Shipping Carton. 8 Install the Wheel Kit... 8 Install the Support Leg... 8 Install the Handles... 8 Connect the Battery... 8 Add Engine Oil... 9 Connecting Liquid Petroleum Gas (LPG) Cylinder Grounding Operation Generator Location Grounding Surge Protection Starting the Engine Connecting Electrical Loads Stopping the Engine Operation at High Altitude Do Not Overload Generator Capacity Power Management Maintenance and Storage Engine Maintenance Oil Spark Plugs Air Filter Spark Arrester Cleaning Adjustments Maintenance Schedule Generator Maintenance Storage Generator Storage Battery Charge the Battery Disconnect the Battery Specifications Engine Specifications Generator Specifications Fuel Oil Spark Plugs Maintenance Valve Clearance An Important Message About Temperature Wiring Diagram Parts Diagram Parts List Engine Parts Diagram Engine Parts List Troubleshooting Warranty Warranty Qualifications Repair/Replacement Warranty Do Not Return The Unit To The Place Of Purchase Warranty Exclusions Normal Wear Installation, Use and Maintenance Other Exclusions Limits of Implied Warranty and Consequential Damage Contact Information Address Customer Service Technical Service... 24

4 Introduction ENGLISH Introduction Congratulations on your purchase of a Champion Power Equipment generator. CPE designs and builds generators to strict specifications. With proper use and maintenance, this generator will bring years of satisfying service. Portable Power Generator This unit is a liquid petroleum gas (LPG) engine driven, alternating current (AC) generator. It is designed to supply electrical power for lighting, appliances, tools and similar equipment. Accessories Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase. To find out more about our covers, power cables, please visit our web site at: This Booklet Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice. Record the model and serial numbers as well as date and place of purchase for future reference. Have this information available when ordering parts and when making technical or warranty inquiries. Champion Power Equipment Support Model Number Serial Number Date of Purchase Purchase Location For Oil Type see Add Engine Oil section. For Fuel Type see Fuel section. 1 REV

5 71330 ENGLISH Manual Conventions This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment. Follow all safety messages to avoid or reduce the risk of serious injury or death. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. If you have questions regarding your generator, we can help. Please call our help line at CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. REV

6 Safety Rules ENGLISH Read this manual thoroughly before operating your generator. Failure to follow instructions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm. DANGER Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death. If you start to feel dizzy or weak, get to fresh air immediately. Operate generator outdoors only in a well ventilated area. DO NOT operate the generator inside any building, including garages, basements, crawlspaces and sheds, enclosure or compartment, including the generator compartment of a recreational vehicle. DO NOT allow exhaust fumes to enter a confined area through windows, doors, vents or other openings. DANGER CARBON MONOXIDE: using a generator indoors CAN KILL YOU IN MINUTES. DANGER Rotating parts can entangle hands, feet, hair, clothing and/or accessories. Traumatic amputation or severe laceration can result. Keep hands and feet away from rotating parts. Tie up long hair and remove jewelry. Operate equipment with guards in place. DO NOT wear loose-fitting clothing, dangling drawstrings or items that could become caught. DANGER Generator produces powerful voltage. DO NOT touch bare wires or receptacles. DO NOT use electrical cords that are worn, damaged or frayed. DO NOT operate generator in wet weather. DO NOT allow children or unqualified persons to operate or service the generator Use a ground fault circuit interrupter (GFCI) in damp areas and areas containing conductive material such as metal decking. Use approved transfer equipment to isolate generator from your electric utility and Notify your utility company before connecting your generator to your power system. Sparks can result in fire or electrical shock. When servicing the generator: Disconnect the spark plug wire and place it where it cannot contact the plug. DO NOT check for spark with the plug removed. Use only approved spark plug testers. Running engines produce heat. Severe burns can occur on contact. Combustible material can catch fire on contact. DO NOT touch hot surfaces. Avoid contact with hot exhaust gases. Allow equipment to cool before touching. Maintain at least three feet of clearance on all sides to ensure adequate cooling. Maintain at least five feet of clearance from combustible materials. Medical and Life Support Uses. In case of emergency, call 911 immediately. NEVER use this product to power life support devices or life support appliances. NEVER use this product to power medical devices or medical appliances. Inform your electricity provider immediately if you or anyone in your household depends on electrical euipment to live. Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency. 3 REV

7 71330 ENGLISH Safety Rules DANGER Liquid Petroleum Gas (LPG) is highly flammable and explosive. Fire or explosion can cause severe burns or death. Unintentional startup can result in entanglement, traumatic amputation or laceration. Liquefied Petroleum Gas (LPG): LPG is highly flammable and explosive. Flammable gas under pressure can cause a fire or explosion if ignited. LPG is heavier than air and can settle in low places while dissipating. LPG has a distinctive odor added to help detect potential leaks quickly. In any petroleum gas fire, flames should not be extinguished unless by doing so the fuel supply valve can be turned OFF. This is because if a fire is extinguished and a supply of fuel is not turned OFF, then an explosion hazard could be created. When exchanging LPG cylinders, be sure the cylinder valve is of the same type. Always keep the LPG cylinder in an upright position. When starting the generator: DO NOT attempt to start a damaged generator. Make certain that the gas supply, air filter, spark plug, fuel lines and exhaust system are properly in place. Make certain that the generator is resting firmly on level ground. When operating the generator: DO NOT move or tip the generator during operation. DO NOT tip the generator or allow oil to spill. When transporting or servicing the generator: Make certain that the fuel shutoff valve is in the off position and the LPG cylinder is not attached. Disconnect the spark plug wire. When storing the generator: Store away from sparks, open flames, pilot lights, heat and other sources of ignition. Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements. Rapid retraction of the starter cord will pull hand and arm towards the engine faster than you can let go. Unintentional startup can result in entanglement, traumatic amputation or laceration. Broken bones, fractures, bruises or sprains could result. When starting engine, pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback. DO NOT start or stop the engine with electrical devices plugged in. CAUTION Exceeding the generator s running capacity can damage the generator and/or electrical devices connected to it. DO NOT overload the generator. Start the generator and allow the engine to stabilize before connecting electrical loads. Connect electrical equipment in the off position, and then turn them on for operation. Turn electrical equipment off and disconnect before stopping the generator. DO NOT tamper with the governed speed. DO NOT modify the generator in any way. CAUTION Improper treatment or use of the generator can damage it, shorten its life and void your warranty. Use the generator only for intended uses. Operate only on level surfaces. DO NOT expose generator to excessive moisture, dust, or dirt. DO NOT allow any material to block the cooling slots. If connected devices overheat, turn them off and disconnect them from the generator. DO NOT use the generator if: Electrical output is lost Equipment sparks, smokes or emits flames Equipment vibrates excessively REV

8 Controls and Features ENGLISH Read this owner s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Generator (1) Fuel Valve Used to turn fuel supply on and off to engine. (2) Choke Used to start the engine. (3) Air Filter Protects the engine by filtering dust and debris from the intake air. (4) Recoil Starter Used to manually start the engine. (5) Oil Filler Cap Check and fill engine oil level. (6) Battery Used to start the engine. Provides 12V DC to the electric starter and receiver control module. (7) Power Panel See Power Panel section. (8) Handle (9) LPG Hose Connector (10) Primer Button 5 REV

9 71330 ENGLISH Controls and Features Power Panel (1) Ignition Switch Used to start or stop the generator. (2) Circuit Breakers Protects the generator against electrical overloads. Push to reset breaker. (3) Intelligauge Three mode digital meter for displaying running hours, voltage and hertz. (4) 120 Volt AC, 30 Amp Twist-Lock Receptacle (NEMA L5-30R) May be used to supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase 60 Hz electrical loads. (5) 120/240 Volt AC, 30 Amp Twist-Lock Receptacle (NEMA L14-30R) May be used to supply electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single phase 60 Hz electrical loads. (6) 120 Volt AC, 20 Amp Duplex (2) (NEMA 5-20R) May be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase 60 Hz electrical loads. (7) Ground Terminal Consult an electrician for local grounding regulations. REV

10 Controls and Features ENGLISH Parts Included Your LPG Powered Generator ships with the following parts: Wheel Kit 10 in. Wheel...2 Flange Bolt (M10x115 for Wheel)...2 Bushing...2 Flat Washer Nut (M10)...2 Support Leg w/vibration Mounts...1 Flange Bolt (M8x16 for Support Leg)...2 Nut (M8 for Support Leg)...2 Handle...2 Flange Bolt (M8x40 for Handle)...2 Nylon Washers (for Handle)...4 Nut (M8 for Handle)...2 Other 5 ft. LPG Hose...1 Oil qt. (1.1 L) Oil Funnel...1 Spark Plug Socket...1 Cap Screw (M5x10 for Battery Terminals)...2 Nut (M5)...2 (Battery Bolts) 7 REV

11 71330 ENGLISH Assembly Your generator requires some assembly. This unit ships from our factory without oil. It must be properly serviced with fuel and oil before operation. If you have any questions regarding the assembly of your generator, call our help line at Please have your serial number and model number available. Install the Support Leg 1. Attach the support leg to the generator frame with cap screws (M8x16) and nuts (M8). 2. Tip the generator slowly so that it rests on the wheels and support leg. Remove the Generator from the Shipping Carton 1. Set the shipping carton on a solid, flat surface. 2. Remove everything from the carton except the generator. 3. Carefully cut each corner of the box from top to bottom. Fold each side flat on the ground to provide a surface area to install the wheel kit and support leg. Install the Wheel Kit CAUTION The wheel kit is not intended for over-the-road use. You will need the following tools to install the wheels: 17 mm wrench OR adjustable wrench (not included) Socket wrench with a 16 mm socket (not included) Pliers (not included) 1. Before connecting fuel and adding oil, tip the generator on it s side. 2. Slide the M10x115 wheel bolt through the washer, sleeve and wheel. 3. Slide the bolt through the mount point on the frame. 4. Fasten securely with the M10 nut. 5. Repeat steps 2-4 to attach the second wheel. Install the Handles 1. Line up the holes on the handle with the holes on the frame. 2. Thread nylon washer through M8x40 flange bolt. 3. Insert bolt through handle and frame. 4. Thread nylon washer onto bolt after it is through the handle and frame. 5. Secure with M8 nut. Tighten. DO NOT over tighten. 6. Repeat steps 1-5 for second handle. Connect the Battery 1. Remove the protective cover from the red (+) lead on the battery. 2. Attach the red (+) lead to the red (+) terminal on the battery with the cap screw (M5x10) and secure with the lock washer (M5). 3. Repeat steps 1-2 for the black ( ) battery lead. REV

12 Assembly ENGLISH Add Engine Oil CAUTION DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil. Damage to the generator as a result of failure to follow these instructions will void your warranty. The recommended oil type is 10W-30 automotive oil. 1. Place the generator on a flat, level surface. Add Engine Oil Cont d. CAUTION The engine is equipped with a low oil shut-off and will stop when the oil level in the crankcase falls below the threshold level. Check oil often during the break-in period. Refer to the Maintenance section for recommended service intervals. The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing. 2. Remove oil fill cap/dipstick to add oil. 3. Add up to 1.16 qt. (1.1 L) of oil and replace oil fill cap/dipstick. DO NOT OVERFILL. 4. Check engine oil level daily and add as needed. 9 REV

13 71330 ENGLISH Assembly Connecting Liquid Petroleum Gas (LPG) Cylinder 1. Make sure the fuel valve on the generator is in the off position. 2. Attach the LPG hose (included) to the LPG hose connector on the side of the generator and tighten with a 19 mm or adjustable wrench. (A) Important: DO NOT use tape or any other type of sealant to seal LPG hose connection. 3. Remove the safety plug or cap from the cylinder valve. 4. Attach the other end of the hose to the LPG connector on the cylinder and hand tighten. Use only standard 20 or 30 pound capacity LP tanks with Type 1, right hand Acme threads. Verify the requalification date on the tank has not expired. All new cylinders must be purged of air and moisture prior to filling. Used cylinders that have not been plugged or kept closed must also be purged. The purging process should be done by a LPG supplier. (Cylinders from an exchange supplier should have been purged and filled properly already). Always position the cylinder so the connection between the valve and the gas inlet won t cause sharp bends or kinks in the hose. CAUTION A Connecting LPG Cylinder Cont d. CAUTION Use approved LPG cylinders equipped with an OPD (overfilling prevention device) valve. Always keep the cylinder in a vertical position with the valve on top and installed at ground level on a flat surface Cylinders must not be installed near any heat source and should not be exposed to sun, rain, and dust. When transporting and storing, turn off the cylinder valve and fuel valve, and disconnect the cylinder. Plug the outlet, usually by a plastic protective cap, if one is available. Keep cylinders away from heat and ventilated when in a vehicle. If there is a strong smell of gas: Close off the gas supply at the cylinder. Use soapy water, which will produce a large bubble at the point of any leak, to check the hose, and connections on the cylinder valve and the generator. Do not smoke or light a cigarette, or check for leaks using a match, open flame source or lighter. Contact a qualified technician to inspect and repair the LPG system if a leak is found, before using the generator. Grounding Your generator must be properly connected to an appropriate ground to help prevent electric shock. Failure to properly ground the generator can result in electric shock. A ground terminal connected to the frame of the generator has been provided on the power panel. For remote grounding, connect of a length of heavy gauge (12 AWG minimum) copper wire between the generator ground terminal and a copper rod driven into the ground. We strongly recommend that you consult with a qualified electrician to ensure compliance with local electrical codes. Do not allow children to tamper or play with the cylinder or hose connections. REV

14 Operation ENGLISH Generator Location NEVER operate the generator inside any building, including garages, basements, crawlspaces and sheds, enclosure or compartment, including the generator compartment of a recreational vehicle. Please consult your local authority. In some areas, generators must be registered with the local utility. Generators used at construction sites may be subject to additional rules and regulations. Generators should be on a flat, level surface at all times. (Even while not in operation) Generators must have at least five feet of clearance from all combustible material. In addition to clearance from all combustible material, generators must also have at least three feet of clearance on all sides to allow for adequate cooling, maintenance and servicing. Generators should never be started or operated in the back of a SUV, camper, trailer, in the bed of a truck (regular, flat or otherwise), under staircases/stairwells, next to walls or buildings, or in any other location that will not allow for adequate cooling of the generator and/or the muffler. DO NOT contain generators during operation. Allow generators to properly cool before transport or storage. Place the generator in a well-ventilated area. DO NOT place the generator near vents or intakes where exhaust fumes could be drawn into occupied or confined spaces. Carefully consider wind and air currents when positioning generator. Failure to follow proper safety precautions may void manufacturer s warranty. Do not operate or store the generator in rain, snow, or wet weather. Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution. During operation the muffler and exhaust fumes produced will become hot. If adequate cooling and breathing space are not supplied, or if the generator is blocked or contained, temperatures can become extremely heated and may lead to fire. Grounding The generator system ground connects the frame to the ground terminals on the power panel. The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin. Electrical devices that require a grounded receptacle pin connection will not function if the receptacle ground pin is not functional. Surge Protection CAUTION Voltage fluctuation may impair the proper functioning of sensitive electronic equipment. Electronic devices, including computers and many programmable appliances use components that are designed to operate within a narrow voltage range and may be affected by momentary voltage fluctuations. While there is no way to prevent voltage fluctuations, you can take steps to protect sensitive electronic equipment. 1. Install UL1449, CSA-listed, plug-in surge suppressors on the outlets feeding your sensitive equipment. Surge suppressors come in single- or multi-outlet styles. They re designed to protect against virtually all short-duration voltage fluctuations. Starting the Engine 1. Make certain the generator is on a flat, level surface. 2. Disconnect all electrical loads from the generator. Never start or stop the generator with electrical devices plugged in or turned on. 3. Make certain the LPG cylinder is in the upright position and on a flat, level surface. 4. Open the valve on the fuel source. 5. Open the FUEL VALVE on the generator. 6. Press and hold the PRIMER BUTTON for 1-2 seconds. 7. Move the CHOKE LEVER to CHOKE. *Only required if temp. below 40 F (4 C). 8. Flip the ignition switch to the ON position. 9. ELECTRIC START: Press and hold the ignition switch to the START position. Release as the engine begins to roll over. If the engine fails to start within five seconds, release the switch and wait at least ten seconds before attempting to start the engine again. 11 REV

15 71330 ENGLISH Operation Starting the Engine Cont d. 10. RECOIL START: Slowly pull the RECOIL HANDLE 2 times, then pull quickly to START the engine. 11. As engine starts, move CHOKE LEVER to RUN. *Only required if temp. below 40 F (4 C). 12. If the engine fails to start the first time, repeat steps If the engine starts but does not run make certain that the generator is on a flat, level surface. The engine is equipped with a low oil sensor that will prevent the engine from running when the oil level falls below a critical threshold. If the temperature is below 40 F (4 C) the choke may be used during the engine warm-up cycle. The CHOKE LEVER should always set to RUN when generator has reached operating temperature and is running smoothly. Keep choke lever in Choke position for only 2 pulls of the recoil starter. After 2 pulls, move choke lever to the Run position for up to the next 3 pulls of the recoil starter. Too much choke leads to an overrich condition due to the lack of incoming air. This will cause the engine not to start. Connecting Electrical Loads 1. Let the engine stabilize and warm up for a few minutes after starting 2. Plug in and turn on the desired 120/240 Volt AC single phase, 60 Hz electrical loads. DO NOT connect 3-phase loads to the generator. DO NOT connect 50 Hz loads to the generator. DO NOT overload the generator. Connecting a generator to your electric utility company s power lines or to another power source may be against the law. In addition this action, if done incorrectly, could damage your generator and appliances and could cause serious injury or even death to you or a utility worker who may be working on nearby power lines. If you plan to run a portable electric generator during an outage, please notify your electric utility company immediately and remember to plug your appliances directly into the generator. Do not plug the generator into any electric outlet in your home. Doing so could create a connection to the utility company power lines. You are responsible for ensuring that your generator s electricity does not feed back into the electric utility power lines. If the generator will be connected to a building electrical system, consult your local utility company or a qualified electrician. Connections must isolate generator power from utility power and must comply with all applicable laws and codes. The supplied 12V 15AH battery does re-charge while the engine is running, but it is also recommended that the battery be fully charged at least once per month. REV

16 Operation ENGLISH Stopping the Engine 1. Turn off and unplug all electrical loads. Never start or stop the generator with electrical devices plugged in or turned on. 2. Let the generator run at no-load for several minutes to stabilize internal temperatures of the engine and generator. 3. Close the OPD valve on the LPG cylinder. 4. Let the engine run until fuel starvation has stopped the engine. This usually takes a few seconds. 5. Turn the Fuel Valve on the generator to the OFF position. Important: Always ensure that the Fuel Valve and the cylinder OPD valve are in the OFF position when the engine is not in use. If the engine will not be used for a period of two (2) weeks or longer, please see the Storage section for proper engine and fuel storage. Operation at High Altitude The density of air at high altitude is lower than at sea level. Engine power is reduced as the air mass and air-fuel ratio decrease. Engine power and output will be reduced approximately 3½% for every 1000 feet of elevation above sea level. This is a natural trend and cannot be changed by adjusting the engine. Do Not Overload Generator Capacity Follow these simple steps to calculate the running and starting watts necessary for your purposes. 1. Select the electrical devices you plan on running at the same time. 2. Total the running watts of these items. This is the amount of power you need to keep your items running. 3. Identify the highest starting wattage of all devices identified in step 1. Add this number to the number calculated in step 2. Surge wattage is the extra burst of power needed to start some electric driven equipment. Following the steps listed under Power Management will guarantee that only one device will be starting at a time. Power Management Use the following formula to convert voltage and amperage to watts: Volts x Amps = Watts To prolong the life of your generator and attached devices, follow these steps to add electrical load: 1. Start the generator with no electrical load attached 2. Allow the engine to run for several minutes to stabilize. 3. Plug in and turn on the first item. It is best to attach the item with the largest load first. 4. Allow the engine to stabilize. 5. Plug in and turn on the next item. 6. Allow the engine to stabilize. 7. Repeat steps 5-6 for each additional item. Never exceed the specified capacity when adding loads to the generator. 13 REV

17 71330 ENGLISH MAINTENANCE AND STORAGE The owner/operator is responsible for all periodic maintenance. Never operate a damaged or defective generator. Oil Cont d. Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole. If using the dipstick to check oil level, DO NOT screw in the dipstick while checking. Tampering with the factory set governor will void your warranty. Improper maintenance will void your warranty. Maintenance, replacement, or repair of emission control devices and systems may be performed by any non-road engine repair establishment or individual. Complete all scheduled maintenance in a timely manner. Correct any issue before operating the generator. For service or parts assistance, contact our help line at Engine Maintenance To prevent accidental starting, remove and ground spark plug wire before performing any service. Oil Change oil when the engine is warm. Refer to the oil specification to select the proper grade of oil for your operating environment. 1. Remove the oil drain plug with a 15 mm socket and extension. 2. Allow the oil to drain completely. 3. Replace the drain plug. 4. Remove oil fill cap/dipstick to add oil. 5. Add 1.16 qt (1.1 L) of oil and replace oil fill cap/dipstick. DO NOT OVERFILL. 6. Dispose of used oil at an approved waste management facility. Spark Plugs 1. Remove the spark plug cable from the spark plug. 2. Use the spark plug tool that shipped with your generator to remove the plug. 3. Inspect the electrode on the plug. It must be clean and not worn to produce the spark required for ignition. 4. Make certain the spark plug gap is mm or ( in.) mm in. 5. Refer to the spark plug recommendation chart when replacing the plug. 6. Carefully thread the plug into the engine. 7. Use the spark plug tool to firmly install the plug. 8. Attach the spark plug wire to the plug. Air filter 1. Remove the snap-on cover holding the air filter to the assembly. 2. Remove the foam element. 3. Wash in liquid detergent and water. Squeeze thoroughly dry in a clean cloth. 4. Saturate in clean engine oil. 5. Squeeze in a clean, absorbent cloth to remove all excess oil. 6. Place the filter in the assembly. 7. Reattach the air filter cover and snap in place. REV

18 Maintenance and Storage ENGLISH Spark Arrester 1. Allow the engine to cool completely before servicing the spark arrester. 2. Remove the three screws holding the cover plate which retains the end of the spark arrester to the muffler. 3. Remove the spark arrester screen. 4. Carefully remove the carbon deposits from the spark arrester screen with a wire brush. 5. Replace the spark arrester if it is damaged. 6. Position the spark arrester in the muffler and attach with the three screws. Failure to clean the spark arrester will result in degraded engine performance. Cleaning CAUTION Federal and local laws and administrative requirements indicate when and where spark arresters are required. When ordered, spark arresters are required for operation of this generator in National Forest lands. In California, this generator must not be used on any forest- covered land, brush-covered land, or grass- covered land unless the engine is equipped with a spark arrester. CAUTION DO NOT spray engine with water. Water can contaminate the fuel system. Use a damp cloth to clean exterior surfaces of the engine. Use a soft bristle brush to remove dirt and oil. Use an air compressor (25 PSI) to clear dirt and debris from the engine. Adjustments The air-fuel mixture is not adjustable. Tampering with the governor can damage your generator and your electrical devices and will void your warranty. CPE recommends that you contact our service line at for all other service and/or adjustment needs. Maintenance Schedule Follow the service intervals indicated in the following maintenance schedule. Service your generator more frequently when operating in adverse conditions. Contact our helpline at to locate the nearest Champion Power Equipment certified service dealer for your generator or engine maintenance needs. Every 8 hours or daily Check oil level Clean around air intake and muffler Check hoses for leaks First 5 Hours Change oil Every 50 hours or every season Clean air filter Change oil if operating under heavy load or in hot environments Every 100 hours or every season Change oil Clean/Adjust spark plug Check/Adjust valve clearance* Clean spark arrester *To be performed by knowledgeable, experienced owners or Champion Power Equipment certified dealers. Generator Maintenance Make certain that the generator is kept clean and stored properly. Only operate the unit on a flat, level surface in a clean, dry operating environment. DO NOT expose the unit to extreme conditions, excessive dust, dirt, moisture or corrosive vapors. CAUTION DO NOT use a garden hose to clean the generator. Water can enter the generator through the cooling slots and damage the generator windings. Use a damp cloth to clean exterior surfaces of the generator. Use a soft bristle brush to remove dirt and oil. Use an air compressor (25 PSI) to clear dirt and debris from the generator. Inspect all air vents and cooling slots to ensure that they are clean and unobstructed. 15 REV

19 71330 ENGLISH Storage Generator Storage 1. Be sure all appliances are disconnected from the generator. 2. Start up and run the generator for a short time. 3. Turn the OPD valve on the cylinder to the Closed position. 4. Let the generator run until fuel starvation has stopped the engine. This usually takes a few seconds. 5. Turn the fuel valve on the generator to the Off position. 6. The generator needs to cool completely before cleaning and storage. 7. Disconnect the fuel hose from the LPG cylinder. 8. Clean the generator according to the maintenance section. 9. Change the oil. 10. Remove the spark plug and pour about 1 2 ounce of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder. 11. Reattach the spark plug. 12. Store the unit in a clean, dry place out of direct sunlight. DANGER Generator exhaust contains odorless and colorless carbon monoxide gas. To avoid accidental or unintended ignition of your generator during periods of storage, the following precautions should be followed: When storing the generator for short or extended periods of time make sure that the LPG cylinder is disconnected from the generator and the Fuel Valve is set in the OFF position. After a period (short or extended) of non-use we recommend that you perform the following maintenance procedures for utmost user safety: Check all hoses and fuel lines before each use for any holes, cracking, abrasions, nicks, cuts, or any other form of damage. If any hose or fuel line is found to be damaged in any way, DO NOT use the unit until the damaged part has been properly replaced. DO NOT try and repair any worn or damaged hose or fuel line, replace it with a new part ONLY. Always check for gas leaks every time a hose or fuel line is replaced, or disconnected and reconnected to any fuel fitting. This will ensure that fuel is properly flowing to the unit and eliminate possible hazards. Maintenance and Storage Generator Storage Cont d. Store LPG tank disconnected from fuel hose and generator. Store LPG tank with the OPD valve in the Closed position. Do not store LPG tank in or around extreme heat. LPG gas is extremely flammable. Do not store LPG tank in or around extreme cold. LPG gas will freeze. Contact with LPG from either the cylinder, excess from the hose, or from any leaks may cause freeze burns on skin. Do not touch or spill LPG on bare skin. Battery This product is equipped with an automatic battery charging circuit. The battery will receive charging voltage when the engine is running. The battery will maintain a proper charge if the unit is used on a regular basis (about once every two weeks). If it is used less frequently, the battery should be connected to a trickle charger or battery maintainer to keep the battery properly charged. If the battery is not able to start the engine, it can be started by manually pulling the engine recoil cord. If the battery voltage is extremely low, the charging circuit may not be able to re-charge the battery. In this case, the battery must be connected to a standard automotive style battery charger for re-charging before it can be used. Charge the Battery For pressure washers equipped with batteries for electric starting, proper battery maintenance and storage should be followed. An automatic battery charger with automatic trickle charging capability should be used to charge the battery. Maximum charging rate should not exceed 1.5 amps. Follow the instructions included with the battery charger. The battery should be fully charged at least once per month. A Float Charger will maintain the battery condition over long storage periods. Disconnect the Battery 1. Remove the protective cover from the black/negative battery lead. 2. Disconnect the black/negative lead from the black/ negative terminal on the battery and store the cap screw (M5x10) and lock washer (M5). 3. Repeat steps 1-2 for the red/positive battery lead. 4. Store the battery in a cool, dry place. REV

20 Specifications ENGLISH Engine Specifications Model...YF188FD-LPG-110 Displacement...389cc Type...4-Stroke OHV Start Type...Electric Start Generator Specifications Model Running Wattage Watts Starting Wattage Watts AC Load /240 V Phase...Single Frequency...60 Hz Gross Weight lbs (93 kg) Net Weight lbs (87.8 kg) Height inches (64.8 cm) Width inches (68.3 cm) Length inches (83 cm) Fuel Use only an approved LPG cylinder equipped with an OPD valve. Oil Use 10W-30 automotive oil. Oil capacity is up to 1.16 qt. (1.1 L). DO NOT OVERFILL. Please reference the following chart for recommended oil types for use in the generator. Spark Plugs OEM spark plug: NHSP F7RTC Replacement spark plug: NGK BPR7ES or equivalent Make certain the spark plug gap is mm or ( in.). Maintenance Valve Clearance Intake: mm ( in.) Exhaust: mm ( in.) Note: Tech bulletin regarding the valve adjustment procedure is on An Important Message About Temperature Your Champion Power Equipment product is designed and rated for continuous operation at ambient temperatures up to 40 C (104 F). When your product is needed your product may be operated at temperatures ranging from -15 C (5 F) to 50 C (122 F) for short periods. If the product is exposed to temperatures outside this range during storage, it should be brought back within this range before operation. In any event, the product must always be operated outdoors, in a well-ventilated area and away from doors, windows and other vents. 17 REV

21 ENGLISH Specifications Wiring Diagram OFF ON ST B Y L G R W B B CIRCUIT BREAKER CIRCUIT BREAKER 25A B 20A B MW2 L L W DUPLEX A DUPLEX B 5-20R L14-30R B W W W MW1 multi-purpose meter W W W L5-30R B FW EXW R Y WL L R + Y YL L R AVR R G/Y R G/Y R R G/Y CIRCUIT BREAKER CIRCUIT BREAKER 25A 20A R R W Transition G/Y G/Y B G/Y G/Y EARTH TERMINAL W DIODE Y B COMBINATION SW B/W W GENERATOR BLOCK B COMBINATION SWITCH ENGINE BLOCK B Br Br R W FUSE 10A B/W CONTROL BOX BLOCK Y BLACK YELLOW BLUE GREEN RED WHITE Br BROWN B/W BLACK WHITE W/G G/Y W/L WHITE GREEN GREEN YELLOW WHITE BLUE In INDIGO SPARKING PLUG IGNITION COIL CHARGE COIL BATTERY STARTER B M B OIL LEVEL SW ST REV

22 Specifications ENGLISH Parts Diagram REV

23 71330 ENGLISH Parts List # Part Number Description Qty Engine Rubber,Fore-Cover Rubber,Fore-Cover Air Guide Flange Bolt M Rotor Assembly Washer ø Spring Washer ø Stator Assembly Flange Bolt M Stator Cover Flange Bolt M End Housing AVR Flange Bolt M Terminal Block Bolt M Washer ø Spring Washer ø Flange Bolt M Generator End Cover Bolt M Pinch Carbon Bursh Assembly Spring Washer ø Washer ø Flange Bolt M Nut M Flange Bolt M Arrester Assembly,Spark Bolt And Washer Assembly M Muffler Assembly Muffler Gasket Nut M Spring Washer ø Washer ø Nut M Holder,Air Cleaner Clip Gas Hose (250 mm) Cut-off Valve Plate Flange Bolt M Knob,Plastics Screw M Spring Washer ø Nut M Washer ø Pressure Reducing Valve Assembly Clamp, Wire Flange Bolt M Big Washer ø Straight Bottom Rubber 2 # Part Number Description Qty Lock Washer ø Grounding Line Motor Mount II Nut M Motor Mount I Nut M Nut M Frame in Wheel Bush ø Bolt M Bolt And Washer Assembly M Nut M Battery 12V15AH Pinch, Rubber Black Wire, Battery Red Wire, Battery Jacket Flange Bolt M Support Leg Vibration Mount Flange Bolt M Gas Hose Flange Bolt M Nylon Washers Handle Cover,Handle Choke Plug Nut M Control Panel Switch Ac.25A Breaker Ac.20A Breaker Intelligauge Receptacle L5-30R Bolt And Washer Assembly M Nut M Receptacle L14-30R Receptacle 5-20R (duplex) Spring Washer ø Washer ø Bolt M Nut M Plug Sheath,Wire Plug Bolt And Washer Assembly M Control Box Plug Screw M Over Voltage Protector Rectifier 1 REV

24 21 REV ENGLISH Specifications Engine Parts Diagram

25 71330 ENGLISH # Part Number Description Qty Recoil Handle Flange bolt M Recoil Starter Cover Recoil Starter Spring Recoil Starter Reel Rope (ø5 1550) Spring,Ratchet Starter Ratchet (Iron) Spring,Ratchet Guide Ratchet Guide Screw, Ratchet Guide Flange bolt M Clip(ø7 ø1) Fan Cover Nut (M16 1.5) Flange bolt Pulley, Starter Ignition Coil Cooling Fan Flywheel (Electric Start EPA) Plate, Coil Coil, Charging Oil Seal (ø35 ø52 8) Wire clip Sheath, Wire Washer (ø12.5 ø20 2) Crankcase Oil Level Sensor Flange bolt Bearing Weight Balancer Crankshaft Gasket, Crankcase Cover Dowel Pin (ø9 14) Air Guide, Right Side Bearing Oil Dipstick Assembly Cover, Crankcase Flange bolt Washer (ø6.4 ø13 1) Shaft,Governor Gear Gear, Governor Clip, Governor Gear Bushing, Governor Gear Connecting Rod Piston Circlip(ø21 ø1) Wrist Pin Ring, Oil Ring, Second Piston Ring,First Piston Dowel Pin(ø12 20) Gasket, Cylinder Head (no asbestos) Air Guide, Lower Cylinder Head Stud.Bolt (M8 49) Spark Plug (F7RTC) Flange bolt Gasket, Cylinder Head Cover 1 # Part Number Description Qty Cylinder Head Cover (CPE) Breather Tube Bolt, Cylinder Head Cover Bolt, Drain (M ) Camshaft (EPA) Lifter, Valve Valve, Intake Valve, Exhaust Push Rod Retainer, Valve Spring (Down) Oil Seal, Valve Spring, Valve Bolt, Rocker Arm Retainer, Intake Valve Spring (Up) Retainer, Exhaust Valve Spring (Up) Rotator, Exhaust Valve Guide Plate Push Rod Shaft, Rocker Arm Retainer, Rocker Arm Rocker Arm, Intake Valve Rocker Arm, Exhaust Valve Washer Screw, Valve Adjustment Flange Nut M Nut, Lock Stud.Bolt (M6 M8 105) Gasket, Insulator (No Asbestos) Insulator, Carburetor Gasket, Carburetor (No Asbestos) Mixer Gasket, Air Cleaner (No Asbestos) Flange Nut M Base, Air Cleaner Seal, Air Cleaner Separator, Air Cleaner Element, Air Cleaner Cover, Air Cleaner Flange bolt M Starter Motor Assembly Relay, Starter (three gear) Spring Washer Flange bolt M Shaft, Governor Arm Washer (ø8.2 ø17 0.8) Oil Seal (ø7 ø14 5) Pin, Shaft Arm, Governor Bolt, Governor Arm (M6 21) Rod Governor Spring, Throttle Return Spring, Governor Air Guide, Upper Negative Pressure Rubber Hose Air Cleaner Assembly Recoil Assembly Gas Tube (Mixer to switch) Hose Clamp 2 REV

26 Troubleshooting ENGLISH Problem Cause Solution Generator will not start No fuel Add fuel Faulty spark plug Replace spark plug Unit loaded during start up Remove load from unit Low oil level Fill crankcase to the proper level Place generator on a flat, level surface Generator starts but runs roughly Choke in the wrong position Adjust choke Spark plug wire loose Attach wire to spark plug Generator shuts down during operation Out of fuel Fill LPG cylinder Low oil level Fill crankcase to the proper level. Place generator on a flat, level surface Generator cannot supply enough power or overheating Generator is overloaded Review load and adjust. See Power Management Insufficient ventilation Check for air restriction. Move to a well ventilated area No AC output Cable not properly connected Check all connections Connected device is defective Replace defective device Circuit breaker is open Reset circuit breaker Faulty brush assembly Replace brush assembly (Service Center) Faulty AVR (auto voltage regulator) Replace AVR (Service Center) Loose wiring Inspect and tighten wiring connections Other Contact the help line Generator gallops Engine governor defective Contact the help line Repeated circuit breaker tripping Overload Review load and adjust. See Power Management Faulty cords or device Check for damaged, bare or frayed wires. Replace defective device For further technical support: Technical Service Mon Fri 8:30 AM 5:00 PM (PST/PDT) Toll Free: tech@championpowerequipment.com 23 REV